A synchronous servo hydraulic bending system

Abstract

The present application relates to the technical field of bending, especially to a synchronous servo hydraulic bending system. The synchronous servo hydraulic bending system comprises a rack, the rack adopts a bolt structure, the bolt connects a square tube and two side plates, a control module, the control module is connected with a wallboard stress compensation module, a wallboard proportional variable compensation module, a hydraulic compensation module, a rear material blocking module, a numerical control module and a bending module, the bending module is connected to a switch module, and the switch module adopts a foot switch. The synchronous servo hydraulic bending system has a very high power density, a maximum working range and a highest load capacity, a small interference profile, and realizes a unit simplification design concept which can obviously save space in a high load application field.

Description

Technical Field

[0001] This invention relates to the field of bending technology, and in particular to a synchronous servo hydraulic bending system. Background Technology

[0002] In existing technologies, the most typical and unavoidable problem with bending machines is the "opening" effect of the wall panel deforming under the reaction force during the bending process. Since the grating ruler is connected to the wall panel, the "opening" effect of the wall panel deforming under the reaction force during bending will cause the grating ruler to move incorrectly. At the same time, existing bending machines are not equipped with an anti-collision system, and in the event of misoperation, the stop finger block cannot be disengaged from the base in time, resulting in damage to the accuracy of the back gauge and failing to guarantee the personal safety of the operator. Summary of the Invention

[0003] To address the aforementioned problems, this invention provides a synchronous servo hydraulic bending system.

[0004] In a first aspect, the present invention provides a synchronous servo hydraulic bending system, which adopts the following technical solution: A synchronous servo hydraulic bending system, comprising: The frame is bolted, and the bolts connect the square tube and the two side plates. The control module is connected to the wall panel stress compensation module, the wall panel proportional deformation compensation module, the hydraulic compensation module, the back gauge module, the CNC module, and the bending module. The bending module is connected to the switch module, which is a foot switch.

[0005] Furthermore, the wall panel stress compensation module includes a grating ruler, which adjusts the reading of the grating ruler to balance the impact of frame deformation on the bending effect during the bending process.

[0006] Furthermore, the hydraulic compensation module includes a three-beam assembly structure, with pins on both sides of the lower beams for connecting to the frame, thereby restricting the relative movement of the plates.

[0007] Furthermore, the wall panel proportional deformation compensation module includes C-shaped frames fixed to both sides of the bottom of the lower crossbeam of the frame by bolts, which are used to connect the grating ruler.

[0008] Furthermore, the bending module includes a CNC bending machine, an upper die fixture, a lower die fixture, and a robotic arm.

[0009] Furthermore, the robotic arm is connected to a robotic arm guide rail for sliding displacement on the guide rail.

[0010] Furthermore, the back gauge module adopts a 2-axis or 4-axis back gauge, and the crossbeam of the back gauge is mainly composed of steel pipe.

[0011] Furthermore, it also includes a front material support bracket, which includes rollers and linear guide rails.

[0012] Furthermore, the foot switch is equipped with a safety lever, which controls the stepping down when the foot is fully inserted, thus achieving safe stepping.

[0013] Furthermore, the control module includes a host computer, which is connected to the bending machine and the robotic arm via a control bus.

[0014] In summary, the present invention has the following beneficial technical effects: This invention, through the aforementioned technical solution, boasts extremely high power density, maximum operating range, and highest load capacity, with a small interference profile, achieving a streamlined unit design that significantly saves space in high-load applications. It also features wide applicability and diverse uses, ranging from handling, palletizing, bending, spot welding to parts processing. Furthermore, it is easy to maintain; KUKA or FANUC robots offer the longest maintenance cycles currently available on the market, reaching up to 20,000 operating hours, maximizing productivity. High precision is also achieved; the robust structure of the KR German-made robot ensures continuous high-precision operation throughout the workspace, while guaranteeing high dynamic performance and unparalleled repeatability. It is more efficient, safer, more flexible, and most importantly, more intelligent. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of a synchronous servo hydraulic bending system according to an embodiment of the present invention. Detailed Implementation

[0016] The present invention will be further described in detail below with reference to the accompanying drawings. Example

[0017] Reference Figure 1 This embodiment of a synchronous servo hydraulic bending system includes: The frame is bolted, and the bolts connect the square tube and the two side plates. The control module is connected to the wall panel stress compensation module, the wall panel proportional deformation compensation module, the hydraulic compensation module, the back gauge module, the CNC module, and the bending module. The bending module is connected to the switch module, which is a foot switch.

[0018] The wall panel stress compensation module includes a grating ruler, which balances the impact of frame deformation on the bending effect by adjusting the grating ruler reading.

[0019] The hydraulic compensation module includes a three-beam assembly structure, with pins on both sides of the lower beams to connect to the frame, and the pins restrict the relative movement of the plates.

[0020] The wall panel proportional deformation compensation module includes C-shaped frames fixed to both sides of the bottom of the lower crossbeam of the frame by bolts, which are used to connect the grating ruler.

[0021] The bending module includes a CNC bending machine, an upper die fixture, a lower die fixture, and a robotic arm.

[0022] The robotic arm is connected to a robotic arm guide rail, which is used for the robotic arm to slide and move on the guide rail.

[0023] The back gauge module adopts a 2-axis or 4-axis back gauge, and the crossbeam of the back gauge is mainly composed of steel pipe.

[0024] It also includes a front material support bracket, which includes rollers and linear guide rails.

[0025] The foot switch is equipped with a safety lever, which controls the stepping down when the foot is fully inserted, thus achieving safe stepping.

[0026] The control module includes a host computer, which is connected to the bending machine and the robotic arm via a control bus.

[0027] Specifically, The frame in this embodiment adopts a bolted structure, with bolts and pins connecting the square tube and the two side plates, ensuring that there is no relative displacement between the square tube and the two side plates during continuous machine operation. The bolted frame structure ensures the strength of the machine and its long-term operational stability.

[0028] The frame material is low-alloy structural steel Q345. Q345 has good comprehensive mechanical properties, good low-temperature performance, and good plasticity and weldability. It is commonly used for medium and low-pressure vessels, oil tanks, vehicles, cranes, mining machinery, power plants, bridges, and other structures bearing dynamic loads, as well as mechanical parts, building structures, and general metal structural components. It can also be used for various structures in cold regions above -40℃.

[0029] G-Reflex wall panel (stress) deformation compensation system The G-Reflex compensation system, applied to the Geshi X-BRAVO, G-TOP, and GPS bending machine series, ensures that the bending angle remains completely consistent throughout the entire length, regardless of changes in sheet thickness, length, or bending position. A typical and unavoidable problem with all bending machines is the "opening" effect of the panel deformation under reaction force during bending. Since the grating ruler is connected to the panel, this "opening" will cause measurement errors. To avoid this, the Geshi X-BRAVO, G-TOP, and GPS bending machine series feature a unique panel (opening) deformation compensation design. The amount of opening deformation is fed back to the CNC for real-time compensation via the G-Reflex system.

[0030] By employing the G-Reflex system, the influence of frame material deformation on the bending result is balanced by adjusting the size of the grating ruler reading.

[0031] The back gauge system, ensuring dimensional accuracy of bent products, is another crucial component of the bending machine. The standard X-Bravo series features a 2-axis (XR) back gauge, guaranteeing the positioning of almost all complex bending workpieces with maximum flexibility, precision, and high speed. A 4-axis (XR-Z1-Z2) back gauge is also available upon request. The back gauge crossbeam utilizes a steel pipe as its main structure, ensuring its robustness and preventing deformation. A specialized aluminum alloy profile above the steel pipe ensures dynamic acceleration of the crossbeam and allows for flexible adjustment of the back gauge's position. The straightness and height of the aluminum alloy crossbeam can be adjusted at any point along its entire length. The front support frame, supported by rollers, slides manually along a linear guide along the Z-axis, and its height can also be easily adjusted using a handle.

[0032] The foot switch meets CE safety requirements and has the following features: A. It has a safety lever; you must put your foot in completely before you can step on it. B. Three-level safety design to prevent accidental actions in a state of panic; The cable is made of flexible shielded conduit, which has good flexibility, corrosion resistance, high temperature resistance, wear resistance, and tensile strength. Each foot switch is equipped with a dual-channel emergency stop switch.

[0033] The hydraulic compensation system works in conjunction with the G-Reflex system during bending to ensure consistent bending angle accuracy throughout the entire length. This system compensates for deformation of the upper and lower crossbeams caused by the reaction force of the workpiece being bent. During bending, if the material type, thickness, length, or bending position changes, the operator can perform a trial bend and adjust and set the compensation value within the CNC system to ensure the upper and lower crossbeams are parallel.

[0034] The lower beam of the bending machine uses a three-piece assembly structure. The gap between the three lower beams uses a special material to ensure that the sheet metal can slide freely relative to each other during deflection compensation. On each side of the lower beam, there are two pins for connection to the frame, which also restrict the relative movement of the sheet metal to the center of the pins. This ensures that when the lower beam is lifted, the highest lifting height is always on the center plane of the lower beam. The pin design ensures optimal compensation while allowing the lower beam to freely return to its natural state when the deflection compensation cylinder is not in operation. A standard manual self-centering fixture is fixed with screws, requiring no adjustment when changing upper or lower dies, and automatically aligns with the upper die. It is used for standard M60 or M90 lower dies. The robotic arm is entirely constructed of cast aluminum and equipped with six programmable motion axes controlled by brushless servo motors. All axes have brakes, and the first three axes are equipped with dedicated limit switches. The orthogonal wrist joint can operate at maximum speed under nominal load (at the point of force).

[0035] The KUKA or FANUC 6-axis robotic arm has a 2700mm reach and is equipped with a 7th-axis guide rail drive system, which is mounted on a guide rail to expand the robotic arm's working area. All motors are servo-controlled axes that generate linkages, and limit settings and braking systems ensure the robotic arm operates at high speeds.

[0036] The application of the G-Flex compensation system in GPS bending machines ensures that the bending angle remains completely consistent throughout the entire length, regardless of changes in bending conditions such as sheet thickness, length, or bending position. For all bending machines, the most typical and unavoidable problem is that during the bending process, the cantilevered wall panel deforms under the reaction force, creating an "opening" effect. If the grating ruler used to measure the stroke is directly fixed to the side wall panel, this "opening" deformation will lead to measurement errors. To avoid this phenomenon, the G-TOP bending machine uses bolts to fix an additional "C" bracket on each side of the bottom of the lower crossbeam to connect the grating ruler. Because this additional "C" bracket is independent of the machine frame structure, it will not deform with the wall panel deformation described above during the bending process, thus ensuring the machine's accuracy. After the G-Flex compensation system is installed, the actual position of the upper crossbeam is detected by two grating rulers installed on an additional "C" frame with an automatic adjustment balancing device and an independent, deformation-free frame. Therefore, during the bending process, the G-Flex compensation system will automatically eliminate the measurement error of the grating rulers according to the amount of deformation of the wall panel "opening".

[0037] The PC-based central control system controls and manages the bending machine, robot, and related components via a bus for independent robotic arm units. It receives production task orders from the user's MES system, manages bending programs, compiles production data, and provides remote services. This improves the overall management of the bending system, reduces operational complexity, provides rapid computing power for the robot's underlying algorithms, and enhances system maintenance capabilities. The PLC host computer primarily provides automated control of the system's various actions through a pre-defined sequence. However, the repeatability of the robot's positioning in 3D space, operating within a PLC programming environment, is affected by factors such as the robot's inherent repeatability, mechanical precision deviations in various transmission components, and operational issues on the production floor. Ultimately, this results in a positioning accuracy within the millimeter range, which fails to meet the bending accuracy requirements. This limits the production to a single product type.

[0038] The PC-based central control system provides a computing environment for storing and backing up big data during the bending process, enabling real-time data calculation and exchange. This is essential for ensuring multi-variety, small-batch production, allowing users to automatically switch between hundreds of bending programs, use them immediately, and automatically store bending data.

[0039] In a PC programming environment, robots can advance from millimeter-level positioning accuracy to 10-micrometer-level control accuracy through low-level algorithm calculations. This is achieved via the "core algorithm Marcos." The repeatability of the robot's bending is ensured by the dynamic calculations of the "core algorithm Marcos" to guarantee three accuracy indicators for bending: 1) Bending angle + / - 0.5° total length 2) Bending parallelism + / - 0.1 mm (overall length) 3) Straightness of bending: + / - 0.1 mm over the entire length. The PC-based control system uses three core algorithms for each bend to control the bending precision in real time, ultimately achieving the effect of multi-variety, small-batch, ready-to-use, and first-piece finished product. This is the core aspect of AI in robot applications.

[0040] The above are all preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made in accordance with the structure, shape and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A synchronous servo hydraulic bending system, characterized in that, include: The frame is bolted, and the bolts connect the square tube and the two side plates. The control module is connected to the wall panel stress compensation module, the wall panel proportional deformation compensation module, the hydraulic compensation module, the back gauge module, the CNC module, and the bending module. The bending module is connected to the switch module, which is a foot switch. The wall panel stress compensation module includes a grating ruler, which balances the impact of frame deformation on the bending effect by adjusting the reading of the grating ruler; The hydraulic compensation module includes a three-beam assembly structure, with pins on both sides of the lower beams to connect to the frame, and the pins restrict the relative movement of the plates. The wall panel proportional deformation compensation module includes C-shaped frames that are fixed to both sides of the bottom of the lower crossbeam of the frame by bolts, which are used to connect the grating ruler; The bending module includes a CNC bending machine, an upper die fixture, a lower die fixture, and a robotic arm; The robotic arm is connected to a robotic arm guide rail, which is used for the robotic arm to slide and move on the guide rail. The back gauge module adopts a 2-axis or 4-axis back gauge, and the crossbeam of the back gauge is mainly composed of steel pipe. It also includes a front material support bracket, which includes rollers and linear guide rails; The foot switch is equipped with a safety lever, which controls the stepping down when the foot is fully inserted, thus achieving safe stepping. The control module includes a host computer, which is connected to the bending machine and the robotic arm via a control bus.

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